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Advances in Corrosion Protection by Coatings
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Advances in Corrosion Protection by Coatings

A special issue of Corrosion and Materials Degradation (ISSN 2624-5558).

Deadline for manuscript submissions: closed (30 September 2024) | Viewed by 14166

Special Issue Editors

Prof. Dr. Wolfram Fürbeth

E-Mail Website
Guest Editor
DECHEMA Research Institute, Theodor-Heuss-Allee 25, 60486 Frankfurt am Main, Germany
Interests: corrosion; corrosion protection; corrosion testing; coatings; nanocoatings; sol-gel coatings; self-healing; anodising; plasma-electrolytic oxidation; electrochemical corrosion investigations; scanning Kelvin probe; electrochemical impedance spectroscopy
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Marjorie Olivier

E-Mail Website
Guest Editor
Materials Science Department, University of Mons, 7000 Mons, Belgium
Interests: corrosion science; coatings; corrosion protection; surface treatment; electrochemistry

Special Issue Information

Dear Colleagues,

Coatings are a very important way of protecting metals against corrosion in many applications. Therefore, the variety of coating methods is relatively broad. Metallic coatings may be used as barrier-type layers, such as nickel-based coatings, or can even provide cathodic protection for an underlying metal, such as zinc-based coatings on steel. Pretreatments are used to provide good adherence and inhibit the delamination processes of organic coatings. In addition, inhibiting compounds and nanocontainers can be added to coatings to bring about self-healing properties. Finally, inorganic coatings, such as anodizing layers and PEO (plasma electrolytic oxidation), can serve as barrier layers on light metals.

This Special Issue is devoted to the corrosion protection of metallic substrates by means of innovative and protective coatings, including their elaboration, morphology, surface characterization, and corrosion protection performance, using electrochemical techniques and/or aging tests.

Completely original submissions from the Coatings community are welcome.

Prof. Dr. Wolfram Fürbeth
Prof. Dr. Marjorie Olivier
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Corrosion and Materials Degradation is an international peer-reviewed open access quarterly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 1000 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

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Further information on MDPI's Special Issue polices can be found here.

Published Papers (7 papers)

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Research

21 pages, 7270 KiB  
Article
Application of Resistometric Sensors for Real-Time Corrosion Monitoring of Coated Materials
by Kateryna Popova, Maria Fátima Montemor and Tomáš Prošek
Corros. Mater. Degrad. 2024, 5(4), 573-592; https://doi.org/10.3390/cmd5040026 - 19 Nov 2024
Viewed by 318
Abstract
Highly sensitive resistometric sensors were applied for the real-time corrosion monitoring of carbon steel protected with a polyolefin coating with and without an inhibitor under static and dynamic atmospheric and immersion conditions. The results were compared with conventional electrochemical impedance spectroscopy (EIS) data. [...] Read more.
Highly sensitive resistometric sensors were applied for the real-time corrosion monitoring of carbon steel protected with a polyolefin coating with and without an inhibitor under static and dynamic atmospheric and immersion conditions. The results were compared with conventional electrochemical impedance spectroscopy (EIS) data. An increase in the coating thickness from 20 µm to 50 µm and an addition of 1wt.% tannic acid significantly improved the coating corrosion stability. Based on the real-time corrosion data, the drying stage of atmospheric exposure in a chloride-rich environment was found to be the most critical. The highest corrosion rate was detected at 50% relative humidity when the electrolyte corrosiveness in coating defects reached the maximum. Resistometric sensors have the potential to become an interesting alternative for evaluating coating performance and degradation mechanisms in both laboratory and industrial applications. Full article
(This article belongs to the Special Issue Advances in Corrosion Protection by Coatings)
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23 pages, 1880 KiB  
Article
Correlation Between the Anticorrosive Performance of Protective Coatings Under Neutral Salt Spray Testing and Outdoor Atmospheric and Immersion Exposure
by Matthias J. Schmid
Corros. Mater. Degrad. 2024, 5(4), 490-512; https://doi.org/10.3390/cmd5040023 - 30 Oct 2024
Viewed by 576
Abstract
Anticorrosive organic coatings are usually tested with accelerated weathering methods to assess their anticorrosive performance. The results of lab testing often do not correlate well with results from field testing, which resembles the conditions of actual use more closely. We tested the correlation [...] Read more.
Anticorrosive organic coatings are usually tested with accelerated weathering methods to assess their anticorrosive performance. The results of lab testing often do not correlate well with results from field testing, which resembles the conditions of actual use more closely. We tested the correlation of the neutral salt spray test (NSS, ISO 9227) and tests for mechanical properties and a 5-year field exposure in four different locations in the atmospheric zone, splash zone and immersion zone using 19 organic coatings for hydraulic steelwork. No correlation was found between the anticorrosive performance under outdoor exposure and the mechanical properties of a coating. The NSS test showed a positive correlation with the results in the field in 6 of 12 cases. For the fresh water testing location in Trier, the correlation proved to be very good. The biggest difference between lab and field testing was observed for zinc-primer-free coatings, which passed in the lab testing and failed in the outdoor testing. This study shows that the NSS test correlates with outdoor exposure only in some cases on a statistically significant level, but the results of NSS testing can be useful in approval testing for protective coating systems using predefined pass/fail criteria. Full article
(This article belongs to the Special Issue Advances in Corrosion Protection by Coatings)
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12 pages, 1756 KiB  
Article
Development of a Reliable Accelerated Corrosion Test for Painted Aluminum Alloys Used in the Aerospace Industry
by Fabienne Peltier and Dominique Thierry
Corros. Mater. Degrad. 2024, 5(3), 427-438; https://doi.org/10.3390/cmd5030019 - 18 Sep 2024
Viewed by 628
Abstract
New environmental regulations have led to major changes in aluminum corrosion protection by prohibiting, for example, Cr(VI). Thus, the assessment of the corrosion behavior of Cr-free systems under atmospheric conditions is a major topic of interest for the aerospace industry. One major difficulty [...] Read more.
New environmental regulations have led to major changes in aluminum corrosion protection by prohibiting, for example, Cr(VI). Thus, the assessment of the corrosion behavior of Cr-free systems under atmospheric conditions is a major topic of interest for the aerospace industry. One major difficulty in this task is the lack of robust and reliable accelerated corrosion test(s) in this field. The aim of the present study is to compare the results of various accelerated corrosion standards (ASTM B117, ISO 4623-2, VCS 1027,149) to results obtained after 5 years of exposure at a marine atmospheric site in Brest, France. Additional accelerated corrosion tests were designed by varying several parameters in the VCS 1027, 149, such as the salt concentration, the time of wetness, and the relative humidity. The different modes of failure obtained in accelerated corrosion tests on the painted samples were then compared to field exposures in a marine atmospheric site. The first results obtained showed that the developed tests are more representative of service conditions than standard tests. Full article
(This article belongs to the Special Issue Advances in Corrosion Protection by Coatings)
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19 pages, 6045 KiB  
Article
Performance of Phenolic-Epoxy Coatings after Exposure to High Temperatures
by Saleh Ahmed, Katerina Lepkova, Xiao Sun, William D. A. Rickard and Thunyaluk Pojtanabuntoeng
Corros. Mater. Degrad. 2024, 5(1), 73-91; https://doi.org/10.3390/cmd5010004 - 29 Feb 2024
Viewed by 2673
Abstract
Phenolic-epoxy coatings, which are designed to protect substrates from thermal damage, are widely applied in many fields. There remains an inadequate understanding of how such coatings change during their service life after exposure to various temperature conditions. To further elucidate this issue, this [...] Read more.
Phenolic-epoxy coatings, which are designed to protect substrates from thermal damage, are widely applied in many fields. There remains an inadequate understanding of how such coatings change during their service life after exposure to various temperature conditions. To further elucidate this issue, this case study investigated the effects of high temperatures on carbon steel panels coated with phenolic epoxy and exposed to different heating conditions. A general trend of decreasing barrier performance was observed after exposure to 150 °C for 3 d, as evidenced by the appearance of cracks on the panel surfaces. In contrast, the coating performance improved after exposure to isothermal conditions (120 °C) or thermal cycling from room temperature to 120 °C, as indicated by the increased low-frequency impedance modulus values of the coating. This unexpected improvement was further examined by characterising the coatings using transform infrared spectroscopy (FTIR), thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), pull-off adhesion tests, and time-of-flight secondary ion mass spectrometry (ToF-SIMS). The maximum pull-off adhesion force (24.9 ± 3.6 MPa) was measured after thermal cycling for 40 d. Full article
(This article belongs to the Special Issue Advances in Corrosion Protection by Coatings)
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27 pages, 25503 KiB  
Article
Effect of Microstructure on Corrosion Behavior of Cold Sprayed Aluminum Alloy 5083
by Munsu Kim, Lorena Perez-Andrade, Luke N. Brewer and Gregory W. Kubacki
Corros. Mater. Degrad. 2024, 5(1), 27-51; https://doi.org/10.3390/cmd5010002 - 16 Jan 2024
Cited by 2 | Viewed by 2745
Abstract
This paper investigates the effect of the microstructure on the corrosion behavior of cold sprayed (CS) AA5083 compared to its wrought counterpart. It has been shown that the microstructure of CS aluminum alloys, such as AA2024, AA6061, and AA7075, affects their corrosion behavior; [...] Read more.
This paper investigates the effect of the microstructure on the corrosion behavior of cold sprayed (CS) AA5083 compared to its wrought counterpart. It has been shown that the microstructure of CS aluminum alloys, such as AA2024, AA6061, and AA7075, affects their corrosion behavior; however, investigations of the corrosion behavior of CS AA5083 with a direct comparison to wrought AA5083 have been limited. The microstructure and corrosion behavior of CS AA5083 were examined by scanning electron microscopy (SEM), transmission electron microscopy (TEM), energy dispersive X-ray spectroscopy (EDS), electron backscattered diffraction (EBSD), electrochemical and immersion tests, and ASTM G67. The CS process resulted in microstructural changes, such as the size and spatial distribution of intermetallic particles, grain size, and misorientation. The refined grain size and intermetallic particles along prior particle boundaries stimulated the initiation and propagation of localized corrosion. Electrochemical tests presented enhanced anodic kinetics with high pitting susceptibility, giving rise to extensive localized corrosion in CS AA5083. The ASTM G67 test demonstrated significantly higher mass loss for CS AA5083 compared to its wrought counterpart due to preferential attack within prior particle boundary regions in the CS microstructure. Possible mechanisms of intergranular corrosion (IGC) propagation at prior particle boundary regions have been discussed. Full article
(This article belongs to the Special Issue Advances in Corrosion Protection by Coatings)
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22 pages, 19748 KiB  
Article
Controlling Lateral Size and Thickness of Layered Double Hydroxide (LDH) Used as Conversion Layer for Corrosion Protection of AZ31 Mg Alloy
by Roya Malekkhouyan, Yoann Paint, Loïc Prince, Maurice Gonon and Marie-Georges Olivier
Corros. Mater. Degrad. 2023, 4(1), 174-195; https://doi.org/10.3390/cmd4010011 - 20 Mar 2023
Cited by 1 | Viewed by 2946
Abstract
In the present study, Mg-Al layered double hydroxide (Mg-Al/LDH) was synthesized on the surface of AZ31 Mg alloy substrate via in-situ hydrothermal treatment. Synthesis parameters were changed to determine their effect on the lateral size of LDH. For this purpose, etching in nitric [...] Read more.
In the present study, Mg-Al layered double hydroxide (Mg-Al/LDH) was synthesized on the surface of AZ31 Mg alloy substrate via in-situ hydrothermal treatment. Synthesis parameters were changed to determine their effect on the lateral size of LDH. For this purpose, etching in nitric acid and anodizing in sodium hydroxide solution were performed as surface pretreatments. Moreover, the influence of LDH solution pH (10 and 11) on the lateral size of LDH coating was investigated. Morphology, chemical composition, and crystalline structure were characterized by scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), Fourier transform infrared (FTIR) spectroscopy, and X-ray diffraction (XRD). The corrosion resistance of the coatings was investigated by H2 measurements, salt spray, and electrochemical impedance spectroscopy (EIS). Moreover, the epoxy coating was applied on the best anti-corrosive LDH sample for assessing the compatibility and effectiveness of LDH on the corrosion properties of the substrate with the epoxy layer. At pH = 11, the lateral size of LDH was smaller than samples at pH = 10. In addition, small-sized LDH, as well as LDH/epoxy coating, revealed enhanced corrosion protection. Full article
(This article belongs to the Special Issue Advances in Corrosion Protection by Coatings)
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13 pages, 16631 KiB  
Article
Development of Photocatalytically Active Anodized Layers by a Modified Phosphoric Acid Anodizing Process for Air Purification
by Stephan Lederer, Sigrid Benfer, Jonathan Bloh, Rezan Javed, Aneta Pashkova and Wolfram Fuerbeth
Corros. Mater. Degrad. 2023, 4(1), 18-30; https://doi.org/10.3390/cmd4010002 - 31 Dec 2022
Cited by 1 | Viewed by 2568
Abstract
One of the key urban air quality issues is pollution by nitrogen oxides (NOx). To reduce NOx, facade cladding could be provided with photocatalytic properties by incorporating titanium dioxide nanoparticles. For this purpose, a modified phosphoric acid anodizing process [...] Read more.
One of the key urban air quality issues is pollution by nitrogen oxides (NOx). To reduce NOx, facade cladding could be provided with photocatalytic properties by incorporating titanium dioxide nanoparticles. For this purpose, a modified phosphoric acid anodizing process (MPAA) was developed for the facade alloy EN AW-5005, in which highly ordered anodized structures with a low degree of arborization and tortuosity were produced. Pore widths between 70 nm and 150 nm and layer thicknesses of about 2–3 μm were obtained. The subsequent impregnation was carried out by dip coating from water-based systems. Depending on the dip-coating parameters and the suspension used, the pores can be filled up to 60% with the TiO2 nanoparticles. Photocatalytic tests according to ISO 22197-1 certify a high photocatalytic activity was obtained with rPCE values > 8 and with rPCE > 2, achieving “photocatalytically active for air purification”. Tests on the corrosion resistance of the anodized coatings with a commercially available aluminum and facade cleaner confirm a protective effect of the anodized coatings when compared with nonanodized aluminum material, as well as with compacted anodized layers. Full article
(This article belongs to the Special Issue Advances in Corrosion Protection by Coatings)
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